Insulating material and method of making same



March 17, 1931. B. STRYKER. .JR 796,631

INSULATING MATERIAL AND METHOD OF MAKING SAME Filed July 3l. 1928 INVENTOR Y my /Q A TTORNEY.

Patented Mar. 17, 1931 UNITED STATES GEORGE B. STRYKER, JR., OF MEMPHIS, TENNESSEE, ASSIGNOR TO THE 'WEATHER- PROOF PRODUCTS COMPANY, OF MEMPHIS, TENNESSEE, A. CORPORATION 0F TENNESSEE INSULATING MATERIAL AND METHOD OF MAKING SAME Application led .Tuly 31,

This invention refers to a composite unit comprising two distinct elements, each having very characteristic individual properties which cannot readily be obtained by the production of one homogeneous body without destroying or weakening one 0r another of these desired qualities.

For this purpose the present invention contemplates the formation of a separate mix for each of these elements, then completely finishing one of the elements and thereupon casting or pressing the mix of the second element over'and partly around'the first element so as to form a unit therewith. In this manner the desired physical qualities of each element are preserved.

The first or base element being made from fibrous material is very light, porous, soft and for these reasons is soundproof and forms a heat and cold insulator.

The second element being made principally from materials that are hard and compact when dry, is flreand waterproof, a perfect insulator` impenetrable by rain and can withstand hail and wind pressure. As all the ingredients may be easily and cheaply obtained and the process of manufacture is very simple, the composite unit, forming the subject matter of the present invention, can be marketed and sold at a very low price.

Furthermore, as said units are not bulky, of comparatively little weight and can be packed very compactly, shipping is facilitated and can be made at low cost.

Depending on the shape and size of the finished composite unit it has a great many different uses such as for wallboards, shingles, surface lining and exterior veneering of buildings, weather sidings, fillers, tiles, and electrical insulators.

In the accompanying drawing the present invention is illustrated, andi Figure 1 represents a vroof shingle in longitudinal section taken along line 1-1 of Figure 2 Figure 2 is a bottom plan view of Figure 1;

Figure 3 a transverse section taken along line 3-3 of Figure 2;

Figure 4 represents a bottom plan view of 1928. Serial No. 296,605.

a tile or wallboard made in accordance with the present invention; and,

Figure 5 is a section taken along line 5-5 of Figure 4.

Reference numeral 10 represents the base or core element and numeral 11 the top or cover element. By means of the marginal flanges 12 the top element 11 grips tightly the edges of the base element 10 on three sides. To insure still further hold between the two elements, the side edges of the base element are preferably provided with indentations or notches as at 13, while the flanges of the top element have corresponding sharp projections 14 engaging said notches. The lower end of the base element is slightly tapered as from 15 to 16 for the purpose of increasing the fiange thickness ofthe top element, thereby giving greater strength and also preventing water from reaching the base element. For the same reason the flanges 12 are made slightly higher as at 18 than the thickness of the pad or base element, which preferably has uniform thickness. In this manner when the shingle is l`id, the bottom surface of the pad or base element will be raised above the supporting structure.

s best seen in Figure 2 of the drawing the finished shingle is preferably rectangular, that is to say, the top element has parallel side edges which merge into the edges of the upper portion 17 of the ,base element, while the remainder of the latter has the same contour as the inner sides of the anges 12.

The body portion 19 of the top or cover element 11 tapers slightly from one end to the other, being thickest at the lower end as at 18 where it is of the same or greater thickness than the base element, while running out to a knife edge a little short of the top edge of the base element 10, or about midway between said edge and the notches 14. At 22 are shown nail holes in the top element for securing the shingles in position.

The preferred size of a shingle unit is 6 by 14 distributed as follows: 2 from the upper edge to the notch 13, 6 between said notch and the point 15 and 6" below the latter. In this manner there will always be three thicknesses ofA shingle near its upper and lower edges of 2" length, while 10" will have double thickness and only 6 will be exposed.

The manner of manufacturing these shingle units is fully disclosed in my copending a plicationz. method of making shingles, erial No. 296,603; and will only be gone into briefiy here below.

The porous base or core element 10 is rst produced from suitable fibrous material, preferably waste paper and cotton fibre, which is compressedl and shaped into a ad of sub stantially vuniform thickness an having a contour as shown in Figures 1 and 2. A plastic mass of cement, fibre, lime and clay., or any other similar material possessing the same properties is then dissolved and thoroughly-4 mixed in water. It is thereupon poured over the finished pad or base element and subjected to high pressure so that the mass is spread compactly over one surface and around three edges of the base element.

In this manner element 11 forms a hardened envelope over the base element 10 forming a complete unit therewith.

As the shingle unit'thus consists of two distinct elements each possessing its own characteristic properties which are not in any manner changed or influenced by the union, the pad or base element through its porousness will thus provide protection against heat, cold and sound disturbances, while the top or cover element protects the roof from the influence of all changing weather condi tions, such as rain, hail, snow, as well as electric disturbances, on account of it being dielectric.

The thick lower or butt end of the shingle unit will cause considerable retardation of rain water flowing down'a roof, as the terposed portion of the cover element, consider ably increases the wearing and lasting qualities of this shingle unit.

This shingle unit combines lightness with great strength and may be easily cut or sawed to suit conditions.

In Figures 4 and 5 a tile or wallboard is represented as produced in accordance with my present invention. As in Figures 1, 2 and 3, the composite unit is made up of two elements 25 and 26 of which the former is a porous pad produced in the same manner as the base element 10 described above and preferably of uniform thickness as indicated and possessing the same properties.

The top or cover element 26 is produced in similar manner and of similar materials as the cover element 1l in Figures l, 2 and 3. As before, it is provided with marginal ianges surrounding the pad 25 o'n all sides and forming a recess between them which is somewhat deeper than the thickness of the pad 25, thus roviding a protecting edge for the latter. s seen in Figure 5 the top or cover element 26 is preferably of uniform thickness, but it may vary from one end to the other or be formed with depressions to suit conditions.

At 28 are shown holes in the cover element 26 for the purpose of securing the composite unit on a wall or the like.

The unit is, in Figures 4 and 5, shown as of square outline, but this may be varied particularly if the unit is used as a tile, whenhexagonal, circular, triangular, or any other contour may be selected.

It is to be understood that the invention as here disclosed is not limited to the details of construction shown and described and that these may be varied widely without departing from the spirit of the invention as deined by the claim.

What is claimed as new is:

A composite heat and weatherproof body comprising a firmly and permanently united base member and top member, the base member consisting of compressed fibrous material. and the top member consist-ing of a hardened mixture of a fibrous material, cement clay and lime forming a Weatherproof body.

In witness whereof, I have hereunto set my hand at Washington, District of Columbia, this twenty-seventh day of July, A. D. nineteen hundred and twenty-eight.

GEORGE B. STRYKER, JR. 

